[jock_rocket]

Hey, I will be removing the stock covers for powder coating soon and just wondered if anyone had any advise on the removal/refit. I have the service manual pages for it but it doesn't seem to mention anything about the clutch actuating arm that goes through the case, am I likely to find any surprises like springs exploding out at me or anything?

 

[Bob's_yer_firkin]

There is a spring in the clutch actuator. It can only really go one way, but its easy to overlook it. The actuator uses a cam and is a bit of a faf to replace as you need to have the slot open when you put the clutch cover back. It will be obvious what I mean when you get the cover off. The aggravating thing I had with mine was an idler gear for the starter motor. When you remove the clutch cover the rod that the gear sits on can come out with the cover. The idler gear then drops into a gap and is fiddly to line up.

On the other side the alternator cover is also a bit of a pita. It has the stator bolted to the cover and the magnet from the rotor keeps it held in place. The power from the alternator comes out via a cable running through a grommet which fits in a groove in the alternator cover. The problem with this is its hard to see if its in place after putting the cover back. When I first swapped my cover I didn't relocate it correctly and only discovered this when I noticed my footpeg was rather slippery. This was due to oil being thrown out! I was lucky I spotted this as it had got onto the back tyre as well. I found that in order to get more freeplay in the alternator cable you need to remove the sprocket cover and undo some nuts hidden behind this. This gives you a bit more movement with the wiring loom. I also used a dab of hylomar blue on the grommet. BTW the first time I did it I removed the rear brake, but you dont have too. Getting the allen bolt out for that was pretty tedious as its easy to scratch the cover if you are not careful.

 

[jock_rocket]

Thanks for the reply, I hate paying for the dealer to do things I can do myself but just don't want to end up with a load of bits on my garage floor that I have no idea where they came from.

 

[PFEN]

a photo to help :wink2:

 

[PFEN]

hope these help you. we can see where the cable may be stuck when reassembling

 

[jock_rocket]

thanks for that, is that some kind of sealant around the cable gland? Did you have to put more on?

 

[Bob's_yer_firkin]

The sealant appears to be the same grey goop Yamaha and Suzuki use to seal up the crankcases. YamaBond I think that was called. I used a dab of blue Hylomar. The pic with the stator is somewhat misleading as that part is actually bolted to the cover and will come off with the cover. If you look carefully you can see the three retaining bolt holes. The power cable is held to the case with a clamp.

 

[PFEN]

one more thing:
take care to the assembly of the crankcase.the threads are fine and delicate. do not screw like a bear.
if you can,use a torque wrench. mine is an old one but work perfect..

 

[jock_rocket]

one more thing:
take care to the assembly of the crankcase.the threads are fine and delicate. do not screw like a bear.
if you can,use a torque wrench. mine is an old one but work perfect..

Wow you're not joking, that's a museum piece :grin2:
I have 1/4" and 1/2" torque wrenches at home, I always use them on the bike.

 

[PFEN]

Wow you're not joking, that's a museum piece :grin2:

the worst is that this tool was modern when I bought it. :nerd:I let you see my age profile ...:wink2:

 

[jock_rocket]

FFFFFFFFFFFFFFFFFFFFUUUUUUUUUUUUUUUU********************!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

Managed to somehow snap my clutch lifter arm when putting the clutch cover on! what a pain!

Fowlers it is then.

 

[muensterDeath]

ffffffffffffffffffffuuuuuuuuuuuuuuuu********************!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

Managed to somehow snap my clutch lifter arm when putting the clutch cover on! What a pain!

Fowlers it is then.

dagger!!!!